Process for alkylation of aromatic hydrocarbons using UZM-35

ABSTRACT

Alkylation processes such as the alkylation of aromatics, are catalyzed by the UZM-35 family of crystalline aluminosilicate zeolites represented by the empirical formula:
 
M m   n+ R r   + Al (1-x) E x Si y O z  
 
where M represents a combination of potassium and sodium exchangeable cations, R is a singly charged organoammonium cation such as the dimethyldipropylammonium cation and E is a framework element such as gallium. These UZM-35 zeolites are active and selective in alkylation processes.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Continuation-In-Part of application Ser. No.12/493,373 filed Jun. 29, 2009, now U.S. Pat. No. 7,982,081, thecontents of which are hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to the use of zeolite UZM-35 in a processfor the alkylation of aromatic hydrocarbons, in particular for theproduction of ethylbenzene or cumene. In the alkylation process, thezeolite UZM-35 may be present in the alkylation catalyst as the solezeolite component or may be combined with at least one additionalzeolite component. The zeolite UZM-35 may be present in the catalyst asunmodified zeolite UZM-35 or as UZM-35 modified zeolite. The UZM-35containing catalyst may take one of several forms, including forexample, a spherical oil-dropped catalyst or an extruded catalyst.

BACKGROUND OF THE INVENTION

Zeolites are crystalline aluminosilicate compositions which aremicroporous and which are formed from corner sharing AlO₂ and SiO₂tetrahedra. Numerous zeolites, both naturally occurring andsynthetically prepared, are used in various industrial processes.Synthetic zeolites are prepared via hydrothermal synthesis employingsuitable sources of Si, Al and structure directing agents such as alkalimetals, alkaline earth metals, amines, or organoammonium cations. Thestructure directing agents reside in the pores of the zeolite and arelargely responsible for the particular structure that is ultimatelyformed. These species balance the framework charge associated withaluminum and can also serve as space fillers. Zeolites are characterizedby having pore openings of uniform dimensions, having a significant ionexchange capacity, and being capable of reversibly desorbing an adsorbedphase which is dispersed throughout the internal voids of the crystalwithout significantly displacing any atoms which make up the permanentzeolite crystal structure. Topological zeolite structures are describedin Atlas of Zeolite Framework Types, which is maintained by theInternational Zeolite Association Structure Commission athttp://www.iza-structure.org/databases/. Zeolites can be used ascatalysts for hydrocarbon conversion reactions, which can take place onoutside surfaces as well as on internal surfaces within the pore.

The alkylation of aromatic hydrocarbons such as benzene with lightolefins such as ethylene and propylene is a very important process in apetrochemical refinery. The production of ethylbenzene is used toprovide a feedstock for styrene production, while alkylation of benzenewith propylene produces isopropylbenzene (cumene). Cumene is animportant feedstock to make phenol as well as a good gasoline blendingcomponent. These alkylation processes typically use a catalyst composedof one of or a combination of 12-ring and 10-ring zeolites structuretypes such as FAU, BEA, MWW, and MFI to enable high conversion and highselectivity to alkylated benzenes. In all these alkylation processes,new catalysts are continuously needed with high overall conversion ofthe feedstock and good selectivity to alkylated benzenes.

Especially advantageous would be a commercially utilizable catalystcontaining 12-membered rings and 10-membered rings in the same3-dimensional structure. Commercial utility is typically seen inaluminosilicate structures which are synthesized in hydroxide media withreadily available structure directing agents. Zeolites which containboth 12-membered and 10-membered rings in 3-dimensional structuresbelong to the CON, DFO, IWR, IWW and MSE structure types. The synthesisof CIT-1, a zeolite of the CON structure type, is described in U.S. Pat.No. 5,512,267 and in J. Am. Chem. Soc. 1995, 117, 3766-79 as aborosilicate form. After synthesis, a subsequent step can be undertakento allow substitution of Al for B. The zeolites SSZ-26 and SSZ-33, alsoof the CON structure type are described in U.S. Pat. No. 4,910,006 andU.S. Pat. No. 4,963,337 respectively. SSZ-33 is also described as aborosilicate. All 3 members of the CON structure type use verycomplicated, difficult to synthesize structure directing agents whichmake commercial utilization difficult. The known member of the DFOstructure type is DAF-1 which is described as an aluminophosphate inChem. Commun. 1993, 633-35 and in Chem. Mater. 1999, 11, 158-63.Zeolites from the IWR and IWW structure types are synthesized only inhydrofluoric acid containing synthesis routes, making commercialutilization difficult.

One particular zeolite of the MSE structure type, designated MCM-68, wasdisclosed by Calabro et al. in 1999 (U.S. Pat. No. 6,049,018). Thispatent describes the synthesis of MCM-68 from dication directing agents,N,N,N′,N′-tetraalkylbicyclo[2.2.2]oct-7-ene-2R,3S:5R,6S-dipyrrolidiniumdication, andN,N,N′,N′-tetraalkylbicyclo[2.2.2]octane-2R,3S:5R,6S-dipyrrolidiniumdication. MCM-68 was found to have at least one channel system in whicheach channel is defined by a 12-membered ring of tetrahedrallycoordinated atoms and at least two further independent channel systemsin which each channel is defined by a 10-membered ring of tetrahedrallycoordinated atoms wherein the number of unique 10-membered ring channelsis twice the number of 12-membered ring channels.

Applicants have successfully prepared a new family of materialsdesignated UZM-35. The topology of the materials is similar to thatobserved for MCM-68. The materials are prepared via the use of simple,commercially available structure directing agents, such asdimethyldipropylammonium hydroxide, in concert with small amounts of K⁺and Na⁺ together using the Charge Density Mismatch Approach to zeolitesynthesis (U.S. Pat. No. 7,578,993).

The alkylation of benzene with ethylene can be performed in gas phaseconditions where all the reactants are in the gaseous phase whilepassing over the solid catalyst or in liquid phase conditions where atleast the benzene is present in the liquid phase while passing over thesolid catalyst. The UZM-35 family of materials is capable of catalyzingthe alkylation of benzene with ethylene in either commercially relevantcondition.

The UZM-35 family of materials is able to provide and maintain highconversion of propylene and high selectivity to isopropylbenzene duringalkylation of benzene with propylene due to its particular pore geometryand framework Si/Al ratio. The UZM-35 zeolite contains significantamounts of Al in the tetrahedral framework, with the mole ratio of Si/Alranging from about 2 to about 12.

SUMMARY OF THE INVENTION

The present invention relates to a process of aromatic alkylation usinga catalyst of the aluminosilicate zeolite designation UZM-35. Theprocess comprises contacting olefinic and alkylatable aromatichydrocarbons with the UZM-35 zeolite at alkylation conditions to give analkylated aromatic product.

The UZM-35 is a microporous crystalline zeolite having athree-dimensional framework of at least AlO₂ and SiO₂ tetrahedral unitsand an empirical composition in the as synthesized and anhydrous basisexpressed by an empirical formula of:M_(m) ^(n+)R_(r) ⁺Al_((1-x))E_(x)Si_(y)O_(z)where M represents a combination of potassium and sodium exchangeablecations, “m” is the mole ratio of M to (Al+E) and varies from about 0.05to about 3, R is a singly charged organoammonium cation selected fromthe group consisting of dimethyldipropylammonium (DMDPA⁺),dimethyldiisopropylammonium (DMDIP⁺), choline, ethyltrimethylammonium(ETMA⁺), diethyldimethylammonium (DEDMA⁺), trimethylpropylammonium,trimethylbutylammonium, dimethyldiethanolammonium, tetraethylammonium(TEA⁺), tetrapropylammonium (TPA⁺), methyltripropylammonium, andmixtures thereof, “r” is the mole ratio of R to (Al+E) and has a valueof about 0.25 to about 2.0, E is an element selected from the groupconsisting of gallium, iron, boron and mixtures thereof, “x” is the molefraction of E and has a value from 0 to about 1.0, “y” is the mole ratioof Si to (Al+E) and varies from greater than 2 to about 12 and “z” isthe mole ratio of O to (Al+E) and has a value determined by theequation:z=(m+r+3+4·y)/2and is characterized in that it has the x-ray diffraction pattern havingat least the d-spacings and intensities set forth in Table A

TABLE A 2θ d (Å) I/Io % 6.45-6.8  13.7-13   m 6.75-7.13 13.1-12.4 m-vs7.86-8.26 11.25-10.7  m 8.64-9.04 10.23-9.78  m  9.51-10.09  9.3-8.77m-vs 10.62-11.23 8.33-7.88 w-m  13.4-14.22 6.61-6.23 w-m 14.76-15.55  6-5.7 w 17.63-18.37 5.03-4.83 w 19.17-19.91 4.63-4.46 w-m 19.64-20.564.52-4.32 m 20.18-21.05  4.4-4.22 w-m  20.7-21.57 4.29-4.12 w-m21.36-22.28 4.16-3.99 vs 22.17-23.6  4.01-3.77 m-s 24.12-25.23 3.69-3.53w  25.6-26.94 3.48-3.31 m 26.37-27.79 3.38-3.21 m 27.02-28.42  3.3-3.14m 27.53-28.89 3.24-3.09 m  28.7-30.09 3.11-2.97 m 29.18-30.72 3.06-2.91w-m 30.19-31.73 2.96-2.82 m 30.83-32.2   2.9-2.78 w 32.81-34.222.73-2.62 w 35.63-36.99 2.52-2.43 w 41.03-42.86  2.2-2.11 w 44.18-45.832.05-1.98 w 44.87-46.57 2.02-1.95 w 46.07-47.35 1.97-1.92 w 48.97-50.421.86-1.81 wand is thermally stable up to a temperature of greater than 400° C. inone embodiment and 600° C. in another embodiment.

The crystalline microporous zeolite described above may be synthesizedby forming a reaction mixture containing reactive sources of M, R, Al,Si and optionally E and heating the reaction mixture at a temperature ofabout 150° C. to about 200° C., or about 165° C. to about 185° C., for atime sufficient to form the zeolite, the reaction mixture having acomposition expressed in terms of mole ratios of the oxides of:aM₂O:bR_(2/p)O:1−cAl₂O₃:cE₂O₃:dSiO₂:eH₂Owhere “a” has a value of about 0.05 to about 1.25, “b” has a value ofabout 1.5 to about 40, “p” is the weighted average valance of R andvaries from 1 to about 2, “c” has a value of 0 to about 1.0, “d” has avalue of about 4 to about 40, “e” has a value of about 25 to about 4000.

Yet another embodiment of the invention is a catalytic process foralkylation of aromatic hydrocarbons using the above-described zeolite.The process comprises contacting the light olefin and the aromatichydrocarbon with the zeolite at conversion conditions to give analkylated aromatic hydrocarbon.

In another embodiment, the invention relates to a process of aromaticalkylation using a catalyst of the aluminosilicate zeolite designationUZM-35HS. The process comprises contacting the hydrocarbon with theUZM-35HS zeolite at aromatic alkylation conditions to give an alkylatedaromatic product. The UZM-35HS is a microporous crystalline zeolitehaving a three-dimensional framework of at least AlO₂ and SiO₂tetrahedral units and an empirical composition on an anhydrous basisexpressed by an empirical formula of:M1_(a) ^(n+)Al_((1-x))E_(x)Si_(y′)O_(z′)where M1 is at least one exchangeable cation selected from the groupconsisting of alkali, alkaline earth metals, rare earth metals, ammoniumion, hydrogen ion and mixtures thereof, “a” is the mole ratio of M1 to(Al+E) and varies from about 0.05 to about 50, “n” is the weightedaverage valence of M1 and has a value of about +1 to about +3, E is anelement selected from the group consisting of gallium, iron, boron, andmixtures thereof, “x” is the mole fraction of E and varies from 0 to1.0, y′ is the mole ratio of Si to (Al+E) and varies from greater thanabout 4 to virtually pure silica and z′ is the mole ratio of O to (Al+E)and has a value determined by the equation:z′=(a·n+3+4·y′)/2and is characterized in that it has the x-ray diffraction pattern havingat least the d-spacings and intensities set forth in Table A:

TABLE A 2θ d (Å) I/Io % 6.45-6.8  13.7-13   m 6.75-7.13 13.1-12.4 m-vs7.86-8.26 11.25-10.7  m 8.64-9.04 10.23-9.78  m  9.51-10.09  9.3-8.77m-vs 10.62-11.23 8.33-7.88 w-m  13.4-14.22 6.61-6.23 w-m 14.76-15.55  6-5.7 w 17.63-18.37 5.03-4.83 w 19.17-19.91 4.63-4.46 w-m 19.64-20.564.52-4.32 m 20.18-21.05  4.4-4.22 w-m  20.7-21.57 4.29-4.12 w-m21.36-22.28 4.16-3.99 vs 22.17-23.6  4.01-3.77 m-s 24.12-25.23 3.69-3.53w  25.6-26.94 3.48-3.31 m 26.37-27.79 3.38-3.21 m 27.02-28.42  3.3-3.14m 27.53-28.89 3.24-3.09 m  28.7-30.09 3.11-2.97 m 29.18-30.72 3.06-2.91w-m 30.19-31.73 2.96-2.82 m 30.83-32.2   2.9-2.78 w 32.81-34.222.73-2.62 w 35.63-36.99 2.52-2.43 w 41.03-42.86  2.2-2.11 w 44.18-45.832.05-1.98 w 44.87-46.57 2.02-1.95 w 46.07-47.35 1.97-1.92 w 48.97-50.421.86-1.81 wand is thermally stable up to a temperature of at least 400° C.

DETAILED DESCRIPTION OF THE INVENTION

Applicants have prepared an aluminosilicate zeolite which has beendesignated UZM-35 whose topological structure is related to MSE asdescribed in Atlas of Zeolite Framework Types, which is maintained bythe International Zeolite Association Structure Commission athttp://www.iza-structure.org/databases/. As is shown in U.S. Ser. No.12/241,302 in detail, UZM-35 is different from MCM-68 in a number of itscharacteristics. The instant microporous crystalline zeolite, UZM-35,has an empirical composition in the as-synthesized form and on ananhydrous basis expressed by the empirical formula:M_(m) ^(n+)R_(r) ⁺Al_((1-x))E_(x)Si_(y)O_(z)where M represents a combination of potassium and sodium exchangeablecations. R is a singly charged organoammonium cation, examples of whichinclude but are not limited to the dimethyldipropylammonium cation(DMDPA⁺), dimethyldiisopropylammonium (DMDIP⁺), choline[(CH₃)₃N(CH₂)₂OH]⁺, ETMA⁺, DEDMA⁺, trimethylpropylammonium,trimethylbutylammonium, dimethyldiethanolammonium,methyltripropylammonium, TEA⁺, TPA⁺ and mixtures thereof and “r” is themole ratio of R to (Al+E) and varies from about 0.25 to about 2.0 while“m” is the mole ratio of M to (Al+E) and varies from about 0.05 to about3. The mole ratio of silicon to (Al+E) is represented by “y” whichvaries from about 2 to about 30. E is an element which is tetrahedrallycoordinated, is present in the framework and is selected from the groupconsisting of gallium, iron and boron. The mole fraction of E isrepresented by “x” and has a value from 0 to about 1.0, while “z” is themole ratio of O to (Al+E) and is given by the equation:z=(m·n+r+3+4·y)/2.Where M is only one metal, then the weighted average valence is thevalence of that one metal, i.e. +1 or +2. However, when more than one Mmetal is present, the total amount of:M_(m) ^(n+)=M_(m1) ^((n1)+)+M_(m2) ^((n2)+)+M_(m3) ^((n3)+)+and the weighted average valence “n” is given by the equation:

$n = \frac{{m_{1} \cdot n_{1}} + {m_{2} \cdot n_{2}} + {m_{3} \cdot n_{3}} + \ldots}{m_{1} + m_{2} + m_{3} + \ldots}$

The microporous crystalline zeolite, UZM-35, is prepared by ahydrothermal crystallization of a reaction mixture prepared by combiningreactive sources of M, R, aluminum, silicon and optionally E. Thesources of aluminum include but are not limited to aluminum alkoxides,precipitated aluminas, aluminum metal, aluminum salts and alumina sols.Specific examples of aluminum alkoxides include, but are not limited toaluminum ortho sec-butoxide and aluminum ortho isopropoxide. Sources ofsilica include but are not limited to tetraethylorthosilicate, colloidalsilica, precipitated silica and alkali silicates. Sources of the Eelements include but are not limited to alkali borates, boric acid,precipitated gallium oxyhydroxide, gallium sulfate, ferric sulfate, andferric chloride. Sources of the M metals, potassium and sodium, includethe halide salts, nitrate salts, acetate salts, and hydroxides of therespective alkali metals. R is an organoammonium cation selected fromthe group consisting of dimethyldiisopropylammonium,dimethyldipropylammonium, choline, ETMA, DEDMA, TEA, TPA,trimethylpropylammonium, trimethylbutylammonium,dimethyldiethanolammonium and mixtures thereof, and the sources includethe hydroxide, chloride, bromide, iodide and fluoride compounds.Specific examples include without limitation dimethyldipropylammoniumhydroxide, dimethyldipropylammonium chloride, dimethyldipropylammoniumbromide, dimethyldiisopropylammonium hydroxide,dimethyldiisopropylammonium chloride, dimethyldiisopropylammoniumbromide, ethyltrimethylammonium hydroxide, diethyldimethylammoniumhydroxide, tetraethylammonium hydroxide, tetrapropylammonium hydroxide,and tetrapropylammonium chloride.

Note that during synthesis, the metal M is +1 valance, specificallypotassium and sodium. However, in an alternative embodiment, thecomposition may undergo additional ion exchange steps, post synthesis,to provide a material with one or more metals, M, having a +2 valance.

The reaction mixture containing reactive sources of the desiredcomponents can be described in terms of molar ratios of the oxides bythe formula:aM₂O:bR_(2/p)O:1−cAl₂O₃:cE₂O₃:dSiO₂:eH₂Owhere “a” varies from about 0.05 to about 1.25, “b” varies from about1.5 to about 40, “c” varies from 0 to 1.0, “d” varies from about 4 toabout 40, “e” varies from about 25 to about 4000, and “p” is theweighted average valence of R and varies from 1 to about 2. If alkoxidesare used, it is preferred to include a distillation or evaporative stepto remove the alcohol hydrolysis products. The reaction mixture is nowreacted at a temperature of about 150° C. to about 200° C., about 165°C. to about 185° C., or about 170° C. to about 180° C., for a period ofabout 1 day to about 3 weeks and preferably for a time of about 5 daysto about 12 days in a sealed reaction vessel under autogenous pressure.After crystallization is complete, the solid product is isolated fromthe heterogeneous mixture by means such as filtration or centrifugation,and then washed with deionized water and dried in air at ambienttemperature up to about 100° C. It should be pointed out that UZM-35seeds can optionally be added to the reaction mixture in order toaccelerate the formation of the zeolite.

A preferred synthetic approach to make UZM-35 utilizes the chargedensity mismatch concept, which is disclosed in U.S. Pat. No. 7,578,993and Studies in Surface Science and Catalysis, (2004), Vol. 154A,364-372. The method disclosed in U.S. Pat. No. 7,578,993 employsquaternary ammonium hydroxides to solubilize aluminosilicate species,while crystallization inducing agents such as alkali and alkaline earthmetals and more highly charged organoammonium cations are oftenintroduced in a separate step. Once some UZM-35 seeds have beengenerated using this approach, the seeds can be used in a single stepsynthesis of UZM-35, using, for example, a combination ofdimethyldiisopropylammonium, dimethyldipropylammonium hydroxide and thealkali cations. The use of commercially availabledimethyldipropylammonium hydroxide to prepare UZM-35 offers a greateconomic advantage over the structure directing agents previouslyemployed(N,N,N′,N′-tetraalkylbicyclo[2.2.2]oct-7-ene-2R,3S:5R,6S-dipyrrolidiniumdication, andN,N,N′,N′-tetraalkylbicyclo[2.2.2]octane-2R,3S:5R,6S-dipyrrolidiniumdication) to prepare aluminosilicates with the MSE topology.Additionally, dimethyldipropyl ammonium hydroxide can be employed as thehydroxide or the chloride in concert with other inexpensiveorganoammonium hydroxides using the charge density mismatch concept toreduce costs even further.

The UZM-35 aluminosilicate zeolite, which is obtained from theabove-described process, is characterized by the x-ray diffractionpattern, having at least the d-spacings and relative intensities setforth in Table A below.

TABLE A 2θ d (Å) I/Io % 6.45-6.8  13.7-13   m 6.75-7.13 13.1-12.4 m-vs7.86-8.26 11.25-10.7  m 8.64-9.04 10.23-9.78  m  9.51-10.09  9.3-8.77m-vs 10.62-11.23 8.33-7.88 w-m  13.4-14.22 6.61-6.23 w-m 14.76-15.55  6-5.7 w 17.63-18.37 5.03-4.83 w 19.17-19.91 4.63-4.46 w-m 19.64-20.564.52-4.32 m 20.18-21.05  4.4-4.22 w-m  20.7-21.57 4.29-4.12 w-m21.36-22.28 4.16-3.99 vs 22.17-23.6  4.01-3.77 m-s 24.12-25.23 3.69-3.53w  25.6-26.94 3.48-3.31 m 26.37-27.79 3.38-3.21 m 27.02-28.42  3.3-3.14m 27.53-28.89 3.24-3.09 m  28.7-30.09 3.11-2.97 m 29.18-30.72 3.06-2.91w-m 30.19-31.73 2.96-2.82 m 30.83-32.2   2.9-2.78 w 32.81-34.222.73-2.62 w 35.63-36.99 2.52-2.43 w 41.03-42.86  2.2-2.11 w 44.18-45.832.05-1.98 w 44.87-46.57 2.02-1.95 w 46.07-47.35 1.97-1.92 w 48.97-50.421.86-1.81 wAs will be shown in detail in the examples, the UZM-35 material isthermally and catalytically stable up to a temperature of at least 400°C. and in another embodiment, up to about 600° C.

As synthesized, the UZM-35 material will contain some of theexchangeable or charge balancing cations in its pores. Theseexchangeable cations can be exchanged for other cations, or in the caseof organic cations, they can be removed by heating under controlledconditions. Because UZM-35 is a large pore zeolite, it is also possibleto remove some organic cations directly by ion exchange. The UZM-35zeolite may be modified in many ways to tailor it for use in aparticular application. Modifications include calcination, ion-exchange,steaming, various acid extractions, ammonium hexafluorosilicatetreatment, or any combination thereof, as outlined for the case ofUZM-4M in U.S. Pat. No. 6,776,975 B1 which is incorporated by referencein its entirety. Properties that are modified include porosity,adsorption, Si/Al ratio, acidity, thermal stability, and the like.

The UZM-35 compositions which are modified by one or more techniquesdescribed in the '975 patent (herein UZM-35HS) are described by theempirical formula on an anhydrous basis of:M1_(a) ^(n+)Al_((1-x))E_(x)Sl_(y′)O_(z′)where M1 is at least one exchangeable cation selected from the groupconsisting of alkali, alkaline earth metals, rare earth metals, ammoniumion, hydrogen ion and mixtures thereof, “a” is the mole ratio of M1 to(Al+E) and varies from about 0.05 to about 50, “n” is the weightedaverage valence of M1 and has a value of about +1 to about +3, E is anelement selected from the group consisting of gallium, iron, boron, andmixtures thereof, “x” is the mole fraction of E and varies from 0 to1.0, y′ is the mole ratio of Si to (Al+E) and varies from greater thanabout 4 to virtually pure silica and z′ is the mole ratio of O to (Al+E)and has a value determined by the equation:z′=(a·n+3+4·y′)/2By virtually pure silica is meant that virtually all the aluminum and/orthe E metals have been removed from the framework. It is well known thatit is virtually impossible to remove all the aluminum and/or E metal.Numerically, a zeolite is virtually pure silica when y′ has a value ofat least 3,000, preferably 10,000 and most preferably 20,000. Thus,ranges for y′ are from 4 to 3,000 preferably greater than 10 to about3,000; 4 to 10,000 preferably greater than 10 to about 10,000 and 4 to20,000 preferably greater than 10 to about 20,000.

The UZM-35 as synthesized or as modified may be in a compositioncomprising the USM-35 as synthesized or as modified, a MFI topologyzeolite and an ERI topology zeolite. Typically, the amount of UZM-35 assynthesized or as modified in the composition will vary from about 55 wt% to about 75 wt. % or from about 55 wt-% to about 90 wt.-%. The amountof MFI zeolite varies from about 20 wt-% to about 35 wt-% of thecomposition or from about 10 wt-% to about 35 wt.-%, and the amount ofERI zeolite varies from about 3 wt-% to about 9 wt-% of the compositionor from about 3 wt-% to about 10 wt.-%. Of course, the sum of the amountof the three zeolites, absent any other impurities, adds up to 100 wt %of the composition.

The UZM-35 zeolite as outlined above or a modification thereof, is usedas a catalyst or catalyst support in various alkylation reactions ofaromatic hydrocarbons. The zeolite preferably is mixed with a binder forconvenient formation of catalyst particles in a proportion of about 5 to100 mass % zeolite and 0 to 95 mass-% binder, with the zeolitepreferably comprising from about 10 to 90 mass-% of the composite. Thebinder should preferably be porous, have a surface area of about 5 toabout 800 m²/g, and be relatively refractory to the conditions utilizedin the hydrocarbon conversion process. Non-limiting examples of bindersare alumina, titania, zirconia, zinc oxide, magnesia, boria,silica-alumina, silica-magnesia, chromia-alumina, alumina-boria,aluminophosphates, silica-zirconia, silica, silica gel, and clays.Preferred binders are amorphous silica and alumina, including gamma-,eta-, and theta-alumina, with gamma- and eta-alumina being especiallypreferred.

The zeolite with or without a binder can be formed into various shapessuch as pills, pellets, extrudates, spheres, etc. Preferred shapes areextrudates and spheres. Extrudates are prepared by conventional meanswhich involves mixing of zeolite either before or after adding metalliccomponents, with the binder and a suitable peptizing agent to form ahomogeneous dough or thick paste having the correct moisture content toallow for the formation of extrudates with acceptable integrity towithstand direct calcination. The dough then is extruded through a dieto give the shaped extrudate. A multitude of different extrudate shapesare possible, including, but not limited to, cylinders, cloverleaf,dumbbell and symmetrical and asymmetrical polylobates. It is also withinthe scope of this invention that the extrudates may be further shaped toany desired form, such as spheres, by any means known to the art.

Spheres can be prepared by the well known oil-drop method which isdescribed in U.S. Pat. No. 2,620,314 which is incorporated by reference.The method involves dropping a mixture of zeolite, and for example,alumina sol, and gelling agent into an oil bath maintained at elevatedtemperatures. The droplets of the mixture remain in the oil bath untilthey set and form hydrogel spheres. The spheres are then continuouslywithdrawn from the oil bath and typically subjected to specific agingtreatments in oil and an ammoniacal solution to further improve theirphysical characteristics. The resulting aged and gelled particles arethen washed and dried at a relatively low temperature of about 50 toabout 200° C. and subjected to a calcination procedure at a temperatureof about 450 to about 700° C. for a period of about 1 to about 20 hours.This treatment effects conversion of the hydrogel to the correspondingalumina matrix.

The interaction of the feed molecules with the catalyst is of greatimportance in catalysis. This interaction may be characterized by thecontact time. Contact time is calculated by dividing the catalyst volumeby the feed flow rate. Lower contact times indicate less interaction ofthe feed with the catalyst, while higher contact times indicate highinteraction of the feed with the catalyst. Selectivity to specificproducts may be altered by altering the contact time. For reactions suchas alkylation of aromatic hydrocarbons, where a feedstock containing analkylatable hydrocarbon and a stream comprising at least one olefin areboth passed over the catalyst, the contact time is calculated using thecombined feed rate. The alkylation and preferably the monoalkylation ofaromatic compounds involves reacting an alkylatable aromatic compoundwith an olefin using the above described zeolitic catalyst. The olefinswhich can be used in the instant process are any of those which containfrom 2 up to about 6 carbon atoms. These olefins may be branched orlinear olefins and either terminal or internal olefins. Preferredolefins are ethylene, propylene, butenes and amylenes.

The alkylatable aromatic compounds may be selected from the groupconsisting of benzene, naphthalene, anthracene, phenanthrene, andsubstituted derivatives thereof, with benzene and its derivatives beingthe most preferred aromatic compound. By alkylatable is meant that thearomatic compound can be alkylated by an olefinic compound. Thealkylatable aromatic compounds may have one or more of the substituentsselected from the group consisting of alkyl groups (having from 1 toabout 20 carbon atoms), hydroxyl groups, and alkoxy groups whose alkylgroup also contains from 1 up to 20 carbon atoms. Where the substituentis an alkyl or alkoxy group, a phenyl group can also be substituted onthe alkyl chain. Although unsubstituted and monosubstituted benzenes,naphthalenes, anthracenes, and phenanthrenes are most often used in thepractice of this invention, polysubstituted aromatics also may beemployed. Examples of suitable alkylatable aromatic compounds inaddition to those cited above include biphenyl, toluene, xylene,ethylbenzene, propylbenzene, butylbenzene, pentylbenzene, hexylbenzene,heptylbenzene, octylbenzene, phenol, cresol, anisole, ethoxy-, propoxy-,butoxy-, pentoxy-, hexoxybenzene, etc.

Reactions involving the alkylation of aromatic hydrocarbons areprocesses well known in the art and include the production ofethylbenzene and cumene. Specific reaction conditions and the types offeeds which can be used in these processes are set forth in (U.S. Pat.No. 7,498,472, U.S. Pat. No. 7,525,003, U.S. Pat. No. 7,525,004, U.S.Pat. No. 7,420,098, U.S. Pat. No. 7,525,005, U.S. Pat. No. 7,525,006)which are all hereby incorporated by reference in their entirety. Thefollowing examples are presented in illustration of this invention andare not intended as undue limitations on the generally broad scope ofthe invention as set out in the appended claims.

Reactions involving the alkylation of aromatic hydrocarbons areprocesses well known in the art and include the production ofethylbenzene and cumene. Specific reaction conditions and the types offeeds which can be used in these processes are set forth in: U.S. Pat.No. 7,498,472, U.S. Pat. No. 7,525,003, U.S. Pat. No. 7,525,004, U.S.Pat. No. 7,420,098, U.S. Pat. No. 7,525,005, U.S. Pat. No. 7,525,006which are all hereby incorporated by reference in their entirety. Thefollowing examples are presented in illustration of this invention andare not intended as undue limitations on the generally broad scope ofthe invention as set out in the claims

The structure of the UZM-35 family of zeolites of this invention wasdetermined by x-ray analysis. The x-ray patterns presented in thefollowing examples were obtained using standard x-ray powder diffractiontechniques. The radiation source was a high-intensity, x-ray tubeoperated at 45 kV and 35 ma. The diffraction pattern from the copperK-alpha radiation was obtained by appropriate computer based techniques.Flat compressed powder samples were continuously scanned at 2° to 56°(2θ). Interplanar spacings (d) in Angstrom units were obtained from theposition of the diffraction peaks expressed as θ where θ is the Braggangle as observed from digitized data. Intensities were determined fromthe integrated area of diffraction peaks after subtracting background,“I_(o)” being the intensity of the strongest line or peak, and “I” beingthe intensity of each of the other peaks.

As will be understood by those skilled in the art the determination ofthe parameter 2θ is subject to both human and mechanical error, which incombination can impose an uncertainty of about ±0.4° on each reportedvalue of 20. This uncertainty is, of course, also manifested in thereported values of the d-spacings, which are calculated from the 2θvalues. This imprecision is general throughout the art and is notsufficient to preclude the differentiation of the present crystallinematerials from each other and from the compositions of the prior art. Insome of the x-ray patterns reported, the relative intensities of thed-spacings are indicated by the notations vs, s, m, and w whichrepresent very strong, strong, medium, and weak, respectively. In termsof 100×I/I_(o), the above designations are defined as:

-   -   w=0-15; m=15-60: s=60-80 and vs=80-100

In certain instances the purity of a synthesized product may be assessedwith reference to its x-ray powder diffraction pattern. Thus, forexample, if a sample is stated to be pure, it is intended only that thex-ray pattern of the sample is free of lines attributable to crystallineimpurities, not that there are no amorphous materials present.

In order to more fully illustrate the invention, the following examplesare set forth. It is to be understood that the examples are only by wayof illustration and are not intended as an undue limitation on the broadscope of the invention as set forth in the appended claims.

EXAMPLE 1

An aluminosilicate reaction solution was prepared by first mixing 27.17g of aluminum hydroxide (27.78 mass-% Al) and 1053.58 gdimethyldipropylammonium hydroxide (18.8 mass-% solution), whilestirring vigorously. After thorough mixing, 505.96 g Ludox™ AS-40 (40mass-% SiO₂) was added. The reaction mixture was homogenized for anadditional hour with a high speed mechanical stirrer, sealed in a Teflonbottle, and placed in an oven overnight at 100° C. Analysis showed thealuminosilicate solution contained 6.16 wt. % Si and 0.67 wt. % Al(Si/Al molar ratio of 8.83).

A 1200 g portion of the above aluminosilicate solution was continuouslystirred. A composite aqueous solution containing 28.56 g of KOH and 3.6g of NaOH dissolved in 150 g distilled water, was added, drop-wise, tothe aluminosilicate solution. After the addition was completed, theresulting reaction mixture was homogenized for 1 hour, transferred to a2000 ml Parr stainless steel autoclave which was heated to 175° C. andmaintained at that temperature for 216 hrs. The solid product wasrecovered by centrifugation, washed with de-ionized water, and dried at100° C.

The solid product was recovered by centrifugation, washed withde-ionized water and dried at 95° C. The product was identified asUZM-35 by xrd. Representative diffraction lines observed for the productare shown in Table 1. The product composition was determined byelemental analysis to consist of the following mole ratios: Si/Al=7.92,Na/Al=0.1, K/Al=0.48.

TABLE 1 2θ d (Å) I/Io % 6.65 13.26 m 6.95 12.69 m 8.10 10.90 m 8.87 9.95m 9.76 9.05 m 10.83 8.13 w 13.76 6.43 w 15.22 5.81 w 18.00 4.92 w 19.464.55 m 19.62 4.52 m 20.06 4.42 m 20.63 4.3 m 21.1 4.20 m 21.76 4.08 vs21.92 4.05 m 22.07 4.03 m 22.55 3.93 m 22.73 3.90 m 23.08 3.85 s 23.423.79 m 23.51 3.77 m 24.04 3.69 m 24.53 3.62 w 25.9 3.43 m 25.99 3.42 w26.27 3.38 m 26.92 3.3 m 27.57 3.23 m 27.76 3.21 m 28.17 3.16 m 28.863.09 w 29.27 3.04 m 29.72 3.00 w 30.26 2.95 w 30.91 2.88 m 31.38 2.84 w33.61 2.68 w 34.65 2.58 w 35.43 2.53 w 36.18 2.48 w 41.77 2.16 w 44.72.02 w 45.32 1.99 w 45.63 1.98 w 46.55 1.94 w 47.62 1.90 w 47.94 1.89 w49.70 1.83 w 51.06 1.78 w

EXAMPLE 2

The UZM-35 of example 1 was calcined at 540° C. for 10 hrs undernitrogen and then air. Representative diffraction lines observed for theproduct are shown in Table 2.

TABLE 2 2θ d (Å) I/Io % 6.72 13.13 m 7.02 12.57 vs 8.0 11.04 m 8.2 10.77m 8.3 10.64 m 8.98 9.83 m 9.87 8.94 vs 11.00 8.03 m 11.29 7.82 w 13.856.38 m 14.17 6.24 w 14.95 5.91 w 15.04 5.88 w 17.72 4.99 w 17.90 4.95 w19.56 4.53 m 19.64 4.51 m 19.70 4.50 m 20.16 4.40 m 20.64 4.29 w 21.154.19 w 21.86 4.06 vs 21.98 4.04 s 22.07 4.02 m 22.62 3.92 m 22.72 3.91 s23.27 3.91 vs 24.08 3.69 m 24.69 3.60 w 25.29 3.51 w 26.28 3.38 m 27.123.28 m 27.66 3.22 m 28.28 3.15 m 28.98 3.07 w 29.36 3.03 m 29.99 2.97 w30.38 2.93 m 31.02 2.88 m 31.54 2.83 w 33.46 2.67 w 34.68 2.58 w 35.072.55 w 35.84 2.50 w 36.29 2.47 w 39.37 2.28 w 41.92 2.15 w 44.96 2.01 w45.72 1.98 w 46.74 1.94 w 47.82 1.9 w 48.13 1.88 w 49.75 1.83 W

EXAMPLE 3

The UZM-35 of example 2 then was ammonium ion-exchanged to exchange Naor K cations for NH₄.

COMPARATIVE EXAMPLE 4

A sample of H-MFI zeolite, bound 66/34 with AlPO₄ was obtained. Thecatalyst consists of 1/16″ diameter spheres. The SiO₂/Al₂O₃ ratio of theMFI is 38.

EXAMPLE 5

The UZM-35 of Example 3 was pressed and meshed to 20-40 mesh prior totesting. For alkylation of benzene with propylene to form cumene, 15 mLof meshed catalyst is mixed with 10 mL of gamma alumina of 20-40 meshand loaded into the reactor. The reactor was pressurized to 500 psigwith N₂ and benzene flow was then started. Once the reactor attained thetarget temperature, the propylene was introduced. Results of the cumenesynthesis tests are shown in Table 3.

TABLE 3 n-Pr Temperature LHSV LHSV B/O Conversion Cumene benzene DIPBHeavy Catalyst (° C.) (olefin) (C₆H₆) ratio (mol %) SelectivitySelectivity Selectivity Selectivity Example 5 148 0.7 5.4 7 ~100 84.8% 600 ppm  7.2%   8% UZM-35 Example 5 148 1.1 4.9 4 ~100 76.3%  800 ppm11.3% 12.4% UZM-35 Example 5 148 0.9 6.6 7 ~100 86.0%  600 ppm  7.2% 6.8% UZM-3 5 Example 5 148 2.0 5.4 2.5 ~100 68.8% 1550 ppm 14.0% 17.2%UZM-35

Not only does the UZM-35 catalyst exhibit good selectivity to cumeneunder these conditions, it is remarkably stable. In 16 hours of reactionat the first condition, no evidence of deactivation was observed.Indeed, over the 60 total hours of reaction time, no deactivation inconversion or change in selectivity due to deactivation was noted.

COMPARATIVE EXAMPLE 6

The MFI catalyst of Example 4, 10.3 mL was loaded into the reactor. Thereactor was pressurized to 500 psig with N₂ and benzene flow wasstarted. Once the reactor attained the target temperature, the ethylenecontaining gas was introduced. The gas feed consisted of 77% CH₄ and 23%C₂H₄. Results of the ethylbenzene synthesis tests are shown in Table 4.

EXAMPLE 7

The UZM-35 of Example 3 then pressed and meshed to 20-40 mesh prior totesting. For alkylation of benzene with ethylene, 15 mL of meshedcatalyst was loaded into the reactor. The reactor was pressurized to 500psig with N₂. Benzene flow was started and once the reactor was up totemperature, the ethylene containing gas was introduced. The gas feedconsisted of 77% CH₄ and 23% C₂H₄. Results of the ethylbenzene synthesistests are shown in Table 4.

TABLE 4 Ethylbenzene Synthesis Temperature WHSV WHSV B/O ConversionEthylbenzene DIEB TIEB Other Catalyst (° C.) (olefin) (C₆H₆) ratio (wt%) Selectivity Selectivity Selectivity Selectivity Example 6 250 1.08.34 3 3% 80% 0.25%  ~0%  19.8% MFI Example 6 279 1.0 8.34 3  8.8 86%1.25%  ~0%  12.8% MFI Example 6 305 1.0 8.34 3 18.5 79%  3.9%  ~0% 17.1% MFI Example 7 190 1.0 8.36 3  6.6 89%  5.6% 0.5%  4.9% UZM-35Example 7 219 1.0 19.5  7 19   88%  4.7% 0.2%  7.1% UZM-35

As can be seen from the results in Table 4, the UZM-35 family ofcatalysts is active at much lower temperatures than typical MFIcatalysts, which is used in commercial EB synthesis, for ethylbenzenesynthesis. In addition, the selectivity of UZM-35 catalysts towardethylbenzene is better than that of MFI. For the MFI catalyst, otherselectivity is composed largely of ethylene oligomers, 2-butylbenzene,and cumene and light alkanes with trace amounts of tert-butylbenzene andxylenes and, in the 305° C. temperature data, toluene, ethyltoluenes andtrimethylbenzenes. For the UZM-35 catalyst, the other selectivity iscomposed of largely of 2-butylbenzene and ethylene oligomers, with traceamounts of cumene and tert-butylbenzene

1. A process for alkylating aromatic hydrocarbons comprising contactinga hydrocarbon feedstock comprising at least alkylatable aromatics and astream comprising olefins having from 2 to about 6 carbon atoms with acatalyst at alkylation conditions and producing an alkylated aromaticproduct wherein the catalyst comprises a UZM-35HS microporouscrystalline zeolite, wherein the UZM-35HS has a three-dimensionalframework of at least AlO₂ and SiO₂ tetrahedral units and an empiricalcomposition on an anhydrous basis expressed by an empirical formula of:M1_(a) ^(n+)Al_((1-x))E_(x)Si_(y′)O_(z′) where M1 is at least oneexchangeable cation selected from the group consisting of alkali,alkaline earth metals, rare earth metals, ammonium ion, hydrogen ion andmixtures thereof, “a” is the mole ratio of M1 to (Al+E) and varies fromabout 0.05 to about 50, “n” is the weighted average valence of M1 andhas a value of about +1 to about +3, E is an element selected from thegroup consisting of gallium, iron, boron, and mixtures thereof, “x” isthe mole fraction of E and varies from 0 to 1.0, y′ is the mole ratio ofSi to (Al+E) and varies from greater than about 4 to virtually puresilica and z′ is the mole ratio of O to (Al+E) and has a valuedetermined by the equation:z′=(a·n+3+4·y′)/2 and is characterized in that it has the x-raydiffraction pattern having at least the d-spacings and intensities setforth in Table A: TABLE A 2θ d (Å) I/Io % 6.45-6.8  13.7-13   m6.75-7.13 13.1-12.4 m-vs 7.86-8.26 11.25-10.7  m 8.64-9.04 10.23-9.78  m 9.51-10.09  9.3-8.77 m-vs 10.62-11.23 8.33-7.88 w-m  13.4-14.226.61-6.23 w-m 14.76-15.55   6-5.7 w 17.63-18.37 5.03-4.83 m 19.17-19.914.63-4.46 w-m 19.64-20.56 4.52-4.32 m 20.18-21.05  4.4-4.22 w-m 20.7-21.57 4.29-4.12 w-m 21.36-22.28 4.16-3.99 vs 22.17-23.6  4.01-3.77m-s 24.12-25.23 3.69-3.53 w  25.6-26.94 3.48-3.31 m 26.37-27.793.38-3.21 m 27.02-28.42  3.3-3.14 m 27.53-28.89 3.24-3.09 m  28.7-30.093.11-2.97 m 29.18-30.72 3.06-2.91 w-m 30.19-31.73 2.96-2.82 m30.83-32.2   2.9-2.78 w 32.81-34.22 2.73-2.62 w 35.63-36.99 2.52-2.43 w41.03-42.86  2.2-2.11 w 44.18-45.83 2.05-1.98 w 44.87-46.57 2.02-1.95 w46.07-47.35 1.97-1.92 w 48.97-50.42 1.86-1.81 w

and is thermally stable up to a temperature of at least 400° C.
 2. Theprocess of claim 1 where the alkylation conditions include a temperatureof from 50° C. to 500° C., a pressure of from about 0 to 6895 kPag(about 0 to 1000 psig), an alkylatable aromatic to olefin mole ratio offrom 10 to 0.1 and a contact time of from about 0.1 seconds to about 1hour.
 3. The process of claim 2 wherein the UZM-35HS zeolite is mixedwith a binder in a proportion of about 5 to 100 mass-% zeolite and 0 to95 mass-% binder.
 4. The process of claim 1 where the alkylatablearomatic of the feedstock comprises an unsubstituted or monosubstitutedbenzene.
 5. The process of claim 1 where the olefin containing streamcontains greater than 20 mol % ethylene and the alkylatable aromaticstream contains greater than 10 mol % benzene or monosubstitutedbenzene.
 6. The process of claim 5 where the alkylatable aromatic isbenzene and the olefin containing stream is propylene.
 7. The process ofclaim 6 where the alkylation conditions include a temperature of from50° C. to 300° C., a pressure of from about 1378 to 5515 kPag (about 200to 800 psig), a benzene to olefin mole ratio of from 10 to 0.3 and acontact time of from about 0.1 seconds to about 1 hour.
 8. The processof claim 1 wherein “x” of the UZM-35HS zeolite is zero.
 9. The processof claim 1 where the selectivity to monoalkylated products is greaterthan about 50 mol %.
 10. The process of claim 1 wherein the UZM-35HS isin a composition comprising the USM-35HS, a MFI topology zeolite and anERI topology zeolite.
 11. The process of claim 10 wherein the amount ofUZM-35HS in the composition ranges from about 55 wt % to about 75 wt. %of the composition, the amount of MFI topology zeolite ranges from about20 wt-% to about 35 wt-% of the composition, and the amount of ERItopology zeolite in the composition ranges from about 3 wt-% to about 9wt-% of the composition.
 12. An alkylation process comprising contactinga feedstock comprising unsubstituted or monosubstituted benzene and anolefin stream comprising ethylene with a catalyst at alkylationconditions and producing an alkylated aromatic product wherein thecatalyst comprises a UZM-35HS microporous crystalline zeolite, whereinthe UZM-35HS has a three-dimensional framework of at least AlO₂ and SiO₂tetrahedral units and an empirical composition on an anhydrous basisexpressed by an empirical formula of:M1_(a) ^(n+)Al_((1-x))E_(x)Sl_(y′)O_(z′) where M1 is at least oneexchangeable cation selected from the group consisting of alkali,alkaline earth metals, rare earth metals, ammonium ion, hydrogen ion andmixtures thereof, “a” is the mole ratio of M1 to (Al+E) and varies fromabout 0.05 to about 50, “n” is the weighted average valence of M1 andhas a value of about +1 to about +3, E is an element selected from thegroup consisting of gallium, iron, boron, and mixtures thereof, “x” isthe mole fraction of E and varies from 0 to 1.0, y′ is the mole ratio ofSi to (Al+E) and varies from greater than about 4 to virtually puresilica and z′ is the mole ratio of O to (Al+E) and has a valuedetermined by the equation:z′=(a·n+3+4·y′)/2 and is characterized in that it has the x-raydiffraction pattern having at least the d-spacings and intensities setforth in Table A: TABLE A Table A 2θ d (Å) I/Io % 6.45-6.8  13.7-13   m6.75-7.13 13.1-12.4 m-vs 7.86-8.26 11.25-10.7  m 8.64-9.04 10.23-9.78  m 9.51-10.09  9.3-8.77 m-vs 10.62-11.23 8.33-7.88 w-m  13.4-14.226.61-6.23 w-m 14.76-15.55   6-5.7 w 17.63-18.37 5.03-4.83 w 19.17-19.914.63-4.46 w-m 19.64-20.56 4.52-4.32 m 20.18-21.05  4.4-4.22 w-m 20.7-21.57 4.29-4.12 w-m 21.36-22.28 4.16-3.99 vs 22.17-23.6  4.01-3.77m-s 24.12-25.23 3.69-3.53 w  25.6-26.94 3.48-3.31 m 26.37-27.793.38-3.21 m 27.02-28.42  3.3-3.14 m 27.53-28.89 3.24-3.09 m  28.7-30.093.11-2.97 m 29.18-30.72 3.06-2.91 w-m 30.19-31.73 2.96-2.82 m30.83-32.2   2.9-2.78 w 32.81-34.22 2.73-2.62 w 35.63-36.99 2.52-2.43 w41.03-42.86  2.2-2.11 w 44.18-45.83 2.05-1.98 w 44.87-46.57 2.02-1.95 w46.07-47.35 1.97-1.92 w 48.97-50.42 1.86-1.81 w

and is thermally stable up to a temperature of at least 400° C.
 13. Theprocess of claim 12 wherein the alkylation conditions include atemperature of from about 50° C. to about 500° C., a pressure of fromabout 0 to about 6895 kPag (about 0 to about 1000 psig), an aromatic toolefin mole ratio of from about 10 to about 0.3 and a contact time offrom about 0.1 seconds to about 1 hour.
 14. The process of claim 12wherein the UZM-35HS zeolite is mixed with a binder in a proportion ofabout 10 to 90 mass % zeolite and about 10 to 90 mass-% binder.
 15. Theprocess of claim 12 where the aromatic feedstock is benzene and theselectivity to ethylbenzene is greater than about 50 mol %.
 16. Theprocess of claim 12 wherein the UZM-35HS is in a composition comprisingthe USM-35HS, a MFI topology zeolite and an ERI topology zeolite. 17.The process of claim 16 wherein the amount of UZM-35HS in thecomposition ranges from about 55 wt % to about 75 wt. % of thecomposition, the amount of MFI topology zeolite ranges from about 20wt-% to about 35 wt-% of the composition, and the amount of ERI topologyzeolite in the composition ranges from about 3 wt-% to about 9 wt-% ofthe composition.
 18. An alkylation process comprising contacting afeedstock comprising unsubstituted or monosubstituted benzene and anolefin stream comprising propylene with a catalyst at alkylationconditions and producing an alkylated aromatic product wherein thecatalyst comprises a UZM-35HS microporous crystalline zeolite, whereinthe UZM-35HS has a three-dimensional framework of at least AlO₂ and SiO₂tetrahedral units and an empirical composition on an anhydrous basisexpressed by an empirical formula of:M1_(a) ^(n+)Al_((1-x))E_(x)Sl_(y′)O_(z′) where M1 is at least oneexchangeable cation selected from the group consisting of alkali,alkaline earth metals, rare earth metals, ammonium ion, hydrogen ion andmixtures thereof, “a” is the mole ratio of M1 to (Al+E) and varies fromabout 0.05 to about 50, “n” is the weighted average valence of M1 andhas a value of about +1 to about +3, E is an element selected from thegroup consisting of gallium, iron, boron, and mixtures thereof, “x” isthe mole fraction of E and varies from 0 to 1.0, y′ is the mole ratio ofSi to (Al+E) and varies from greater than about 4 to virtually puresilica and z′ is the mole ratio of O to (Al+E) and has a valuedetermined by the equation:z′=(a·n+3+4·y′)/2 and is characterized in that it has the x-raydiffraction pattern having at least the d-spacings and intensities setforth in Table A: TABLE A Table A 2θ d (Å) I/Io % 6.45-6.8  13.7-13   m6.75-7.13 13.1-12.4 m-vs 7.86-8.26 11.25-10.7  m 8.64-9.04 10.23-9.78  m 9.51-10.09  9.3-8.77 m-vs 10.62-11.23 8.33-7.88 w-m  13.4-14.226.61-6.23 w-m 14.76-15.55   6-5.7 w 17.63-18.37 5.03-4.83 w 19.17-19.914.63-4.46 w-m 19.64-20.56 4.52-4.32 m 20.18-21.05  4.4-4.22 w-m  20.7-21.570 4.29-4.12 w-m 21.36-22.28 4.16-3.99 vs 22.17-23.6 4.01-3.77 m-s 24.12-25.23 3.69-3.53 w  25.6-26.94 3.48-3.31 m26.37-27.79 3.38-3.21 m 27.02-28.42  3.3-3.14 m 27.53-28.89 3.24-3.09 m 28.7-30.09 3.11-2.97 m 29.18-30.72 3.06-2.91 w-m 30.19-31.73 2.96-2.82m 30.83-32.2   2.9-2.78 w 32.81-34.22 2.73-2.62 w 35.63-36.99 2.52-2.43w 41.03-42.86  2.2-2.11 w 44.18-45.83 2.05-1.98 w 44.87-46.57 2.02-1.95w 46.07-47.35 1.97-1.92 w 48.97-50.42 1.86-1.81 w

and is thermally stable up to a temperature of at least 400° C.
 19. Theprocess of claim 18 where the alkylation conditions include atemperature of from about 50° C. to about 300° C., a pressure of fromabout 1378 to about 5515 kPag (about 200 to about 800 psig), an aromaticto olefin mole ratio of from about 10 to about 0.3 and a contact time offrom about 0.1 seconds to about 1 hour.
 20. The process of claim 18wherein the UZM-35 zeolite is mixed with a binder in a proportion ofabout 10 to 90 mass % zeolite and about 10 to 90 mass-% binder.
 21. Theprocess of claim 18 wherein the aromatic feedstock is benzene and theselectivity to cumene is greater than 50 mol %.
 22. The process of claim18 wherein the UZM-35HS is in a composition comprising the USM-35HS, aMFI topology zeolite and an ERI topology zeolite.
 23. The process ofclaim 22 wherein the amount of UZM-35HS in the composition ranges fromabout 55 wt % to about 75 wt. % of the composition, the amount of MFItopology zeolite ranges from about 20 wt-% to about 35 wt-% of thecomposition, and the amount of ERI topology zeolite in the compositionranges from about 3 wt-% to about 9 wt-% of the composition.